Methods for preparing fuel compositions from renewable sources, and related systems

ABSTRACT

A method for producing a fuel composition from a feedstock which may contain biomass and municipal solid waste is described. The method includes the step of pyrolyzing the feedstock in the presence of a transition metal, using microwave energy, so that the level of oxygen in at least one product of the pyrolysis is reduced. An integrated process is also described, in which the transition metal can be regenerated. Moreover, pyrolysis products such as bio-oils can be upgraded to liquid fuel compositions. Related systems for producing fuel compositions are also described.

BACKGROUND OF THE INVENTION

This invention generally relates to fuel compositions. Some specificembodiments of the invention are directed to methods for preparingliquid fuels from biomass or municipal solid waste materials.

In view of the projected, long-term shortages in the availability ofquality fossil fuels, there has been tremendous interest in thedevelopment of renewable sources of fuels. One of the most attractivesources for such fuel is biomass, which can be used to prepare a varietyof different types of fuel—some of which are referred to as “biofuel”,or “biodiesel”. Another potential source is municipal solid waste (MSW),which usually contains primarily household waste, but which can alsoinclude commercial waste.

There are two main routes for producing liquid fuels from biomassmaterials. The indirect route involves biomass gasification. In such aprocess, the raw material is gasified under partial combustionconditions, to produce a syngas based on carbon monoxide and hydrogen.Air-blown circulating fluidized bed (CFB) gasifiers are oftenwell-suited for small-scale biomass gasification. The syngas can then beconverted into a liquid fuel by way of Fischer-Tropsch (FT) synthesis.

While the indirect method is useful in many situations, it oftenrequires very high temperatures, e.g., 800° C.-1,700° C., depending onthe type of gasifier. There may also be difficulties in reliably feedingthe raw material into the pressurized gasifier. Moreover, for the CFBprocesses, nitrogen dilution can be problematic. Also, high tarconcentrations in the product gas often necessitates subsequent gasclean-up steps, which can increase capital costs.

Pyrolysis is another method for producing the liquid fuels from biomass,and this technique can be thought of as a “direct method”. The processitself is known in the art, and involves the thermal decomposition ofbiomass or other carbonaceous materials. The process is carried out inthe absence of oxygen, or in the presence of significantly reducedlevels of oxygen, as compared to conventional combustion processes. Thetemperatures involved are much lower than for gasification, e.g., about400° C.-600° C. The primary products of pyrolysis are oils, light gases,and char. As further described below, the vapor products of pyrolysiscan be condensed to a liquid product, i.e., a “bio-oil”, bycondensation, for example.

Bio-oils (“pyrolysis oils”) are valuable fuel precursors, but they arealso quite distinct from hydrocarbon-based petroleum fuels. The highoxygen content of the pyrolysis oils, e.g., up to about 50% by weight,would take such materials outside the conventional definition for ahydrocarbon. These relatively high levels of oxygen limit the use of thecompositions, in applications such as transportation fuels (gasoline anddiesel fuel). In most instances, the oxygen content would have to bereduced considerably, to allow additional upgrading steps to form theconventional fuels.

In view of these considerations, new processes for preparing fuels,e.g., liquid fuels, from biomass or MSW materials would be welcome inthe art. For many end use applications, the processes should be based inpart on pyrolysis reactions. Moreover, they should minimize the amountof oxygen content found in one or more of the pyrolysis products. Thenew processes should also be capable of economic implementation, andshould be compatible with other procedures, e.g., fuel upgrading stepsof the pyrolysis products.

BRIEF DESCRIPTION OF THE INVENTION

One embodiment of the invention is directed to a method for producing afuel composition from a feedstock which comprises biomass, municipalsolid waste (MSW), or a combination thereof. The method comprises thestep of pyrolyzing the feedstock in the presence of a transition metal,using microwave energy, so that the level of oxygen in at least oneproduct of the pyrolysis is reduced.

An integrated process for producing a fuel composition from a feedstockmaterial, comprising at least one of biomass and municipal solid waste,constitutes another embodiment of the invention. The process comprisesthe steps of:

a) pyrolyzing the feedstock in the presence of a transition metal, usingmicrowave energy, so that the level of oxygen in at least one product ofthe pyrolysis is reduced; while the transition metal is oxidized;

-   -   wherein the pyrolysis product comprises bio-oils, light        hydrocarbons, and char;

b) regenerating the transition metal by subjecting the oxidizedtransition metal to a reduction reaction, wherein the reduction reactionis at least partly energized by the combustion of a portion of the lighthydrocarbons; and

c) upgrading the bio-oil product to a liquid fuel, by an upgradingprocess which comprises hydro-treating, hydro-isomerization; andseparation of isomerization products.

An additional embodiment of the invention relates to a system forproducing a fuel composition from a feedstock material comprising atleast one of biomass and municipal solid waste (MSW). The systemcomprises:

(i) a pyrolysis reactor, adapted to accept a feedstock of biomass orMSW, or combinations thereof; and to convert the feedstock to pyrolysisproducts;

(ii) a microwave source adapted to supply microwave energy to thepyrolysis reactor;

(iii) a transition metal supply unit in communication with the pyrolysisreactor, to supply a selected amount of transition metal duringpyrolysis; and

(iv) at least one upgrading unit in communication with the pyrolysisreactor, to convert at least one of the pyrolysis products to a liquidfuel composition.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a process block flow diagram of the steps in an illustrativeprocess for converting a feedstock to a fuel in a microwave-assistedpyrolysis process.

FIG. 2 is a plot of transition metal levels as a function oftemperature, under equilibrium conditions, for a biomass pyrolysisreaction.

DETAILED DESCRIPTION OF THE INVENTION

The compositional ranges disclosed herein are inclusive and combinable(e.g., ranges of “up to about 25 wt %”, or, more specifically, “about 5wt % to about 20 wt %”, are inclusive of the endpoints and allintermediate values of the ranges). Weight levels are provided on thebasis of the weight of the entire composition, unless otherwisespecified; and ratios are also provided on a weight basis. Moreover, theterm “combination” is inclusive of blends, mixtures, alloys, reactionproducts, and the like.

Furthermore, the terms “first,” “second,” and the like, herein do notdenote any order, quantity, or importance, but rather are used todistinguish one element from another. The terms “a” and “an” herein donot denote a limitation of quantity, but rather denote the presence ofat least one of the referenced items. The modifier “about” used inconnection with a quantity is inclusive of the stated value, and has themeaning dictated by context, (e.g., includes the degree of errorassociated with measurement of the particular quantity).

Moreover, in this specification, the suffix “(s)” is usually intended toinclude both the singular and the plural of the term that it modifies,thereby including one or more of that term (e.g., “the compound” mayinclude one or more compounds, unless otherwise specified). Referencethroughout the specification to “one embodiment”, “another embodiment”,“an embodiment”, and so forth, means that a particular element (e.g.,feature, structure, and/or characteristic) described in connection withthe embodiment is included in at least one embodiment described herein,and may or may not be present in other embodiments. In addition, it isto be understood that the described inventive features may be combinedin any suitable manner in the various embodiments.

As used herein, the term “biomass” may include a variety of renewableenergy sources. Usually (though not always), biomass refers to materialsderived from plants. In general, biomass can include materials such aswood and tree based materials, forest residues, agricultural residuesand energy crops. The wood and tree materials and forest residues mayinclude wood, woodchips, saw dust, bark or other such products fromtrees, straw, grass, and the like. Agricultural residue and energy cropsmay further include short rotation herbaceous species, husks such asrice husk, coffee husk, etc., maize, corn stover, oilseeds, residues ofoilseed extraction, and the like. The oilseeds may be typical oilbearing seeds like soybean, camolina, canola, rapeseed, corn,cottonseed, sunflower, safflower, olive, peanut, and the like.

The term “municipal solid waste” (MSW), can include household waste,along with commercial wastes, collected by a municipality within a givenarea. MSW can include inorganic and organic components in the form ofcellulosic materials, metals (both ferrous and non-ferrous), plastic,glass, food, and others. MSW can be derived from packaging materials,e.g., mixed cellulosic paperboard packaging materials, corrugatedpaperboard, plastic wrap, plastic bottles, steel cans, aluminum cans,other plastic or metal packaging materials, glass bottles, and containerwaste. Such waste can be any combination of plastic, metal, and paper.Material typically available in municipal waste that can be used eitheras a feedstock for fuel production, or as a valuable recycled product,includes cellulosic fiber or pulp, paperboard, corrugated paperboard,newsprint, glossy magazine stock, and a variety of other cellulosicboard or sheet materials, which can include polymers, fillers, dyes,pigments, inks, coatings, and a variety of other materials. Other typesof solid waste can also be processed using the apparatus and techniquesherein. Those include medical waste, manure, and carcasses. The term“feedstock”, as used herein, can include biomass, MSW, or a combinationthereof. Usually, the feedstock comprises at least about 10% biomass, bysolids-weight; and in some preferred embodiments, at least about 75%.

The present invention calls for pyrolysis of the feedstock. As mentionedabove, pyrolysis (sometimes referred to as “destructive distillation”)involves the thermal decomposition of biomass. The process is carriedout in the absence of oxygen, or in the presence of significantlyreduced levels of oxygen. The pyrolysis temperature can vary, but isusually in the range of about 400° C.-600° C. A variety of pyrolysisprocesses can be used for the present invention.

In some preferred embodiments, the feedstock is subjected to a fastpyrolysis reaction. Fast pyrolysis is known in the art and described,for example, in U.S. Pat. No. 6,844,420 (Freel et al) and U.S. Pat. No.5,961,786 (Freel et al), and in U.S. Patent Publication 2009/0227766(Bridgwater et al), all of which are incorporated herein by reference.The process involves the rapid thermal decomposition of organiccompounds, in the absence of oxygen, or minimal oxygen, to produce thepyrolysis products, i.e., oils, light gases, and char. In mostinstances, the feedstock should be relatively dry, with less than about10% moisture. Moreover, in some embodiments, the particle size of thefeedstock is best maintained at less than about 1 mm, and preferably,less than about 0.5 mm. If necessary, conventional techniques can beused to reduce the average particle size to this level.

As further detailed below, the pyrolysis reaction is carried out, usingmicrowave energy. Microwave energy is ideally suited to provide highheating rates. The energy is transferred through a feedstock materialelectro-magnetically, and not generally as a convective force or aradiative force. Therefore, the rate of heating is not limited by thesurface transfer, and the uniformity of heat distribution is greatlyimproved. Heating times can be reduced to less than about 1% of thatrequired for conventional techniques.

Typically, the energy supplied by a microwave source is provided in twoforms: heat energy, and plasma energy. The presence of the microwaveplasma appears to be especially suitable in fast pyrolysis techniques,because it lowers the temperature threshold for chemical reactions whichtake place in the reactor.

The temperature for fast pyrolysis can vary, but is usually below about600° C., and in some preferred embodiments, below about 550° C. Atypical temperature range is about 400° C. to about 500° C. In mostembodiments, the relatively hot product stream is then rapidly quenched,as described in U.S. Pat. No. 5,961,786. The quenching step can becarried out by various techniques, e.g., the use of a condensing column.The condensing column may be cooled by a circulating water (or otherliquid) system. Cooling can also be carried out by contact with aportion of the pyrolysis oil which is initially formed.

In a typical process available in the art—conventional pyrolysis or fastpyrolysis—the overall oxygen content for the pyrolysis products can bequite high, e.g., up to about 50% by weight. As noted above, the highoxygen content can make it very difficult to upgrade the pyrolysisproducts (especially the bio-oils) to conventional liquid fuels.

According to primary embodiments of the present invention, pyrolysis ofthe feedstock is carried out in the presence of at least one transitionmetal. A number of transition metals are possible. Examples includecopper, nickel, cobalt, manganese, iron, and zinc. The choice of aparticular transition metal will depend on various factors. Some ofthese factors are as follows: the composition of the feedstock; thepyrolysis temperature; and the temperature at which metal oxidation andregeneration of the metal (by reduction) would be expected to occur, asdescribed below. Additional factors include a review of the oxidationpotential and reduction potential of the metal for a given situation. Insome specific embodiments, the transition metal is selected from thegroup consisting of iron, nickel, and copper. The preferred transitionmetal is usually iron. Some of the factors listed above are alsoinfluenced by the physical form of the transition metal to be used.Usually, the transition metal is employed in particulate form, having anaverage particle diameter no greater than about 5 mm, and in someinstances, no greater than about 1 mm.

The transition metal can be supplied to the pyrolysis reactor in anumber of different ways. In some cases, it can be supplied in metallicform; while in other situations, it can be supplied as an oxide, whichis reduced (e.g., with a reducing agent) before coming into contact withthe pyrolysis products. Various complexes of the metal could be used aswell. As described below, the transition metal can be readilyincorporated into fluidized bed or entrained-bed tubular reactors whichare sometimes used for fast pyrolysis.

The amount of transition metal which is employed will depend on avariety of factors. They include: the size and composition of thefeedstock; the oxygen content of the feedstock; the desired level towhich oxygen is to be reduced in the pyrolysis products; the type ofpyrolysis reactor; and the temperature at which pyrolysis is carriedout.

As mentioned above, the presence of the transition metal results in avery desirable decrease in the level of oxygen in at least one productof the pyrolysis, e.g., the pyrolysis oils. In some embodiments, theoverall feedstock composition may initially contain oxygen at a level ofabout 10% to about 50%, based on total solids weight. After thepyrolysis step which includes the presence of the transition metal, theamount of oxygen can be reduced by at least about 50% of the amountbefore pyrolysis. (As those skilled in the art understand, the amount ofoxygen in feedstock materials and pyrolysis products can be measured byvarious, well-known techniques, e.g., ultimate analysis)

Although the inventors do not wish to be bound by any operationaltheory, it appears that the transition metal functions according tooxygen scavenging chemistry. Moreover, the use of a transition metalappears to be very advantageous in a pyrolysis process which relies onmicrowave energy. The particles of the transition metal are veryelectrically conductive, and favor the formation of microplasma aroundthe particles, in the presence of the microwave energy. It also appearsthat the transition metal has a catalytic effect on biomass pyrolysis,which also results in decreased oxygen content in the bio-oil product.Thus, the presence of a transition metal like iron may play a dual rolein the overall pyrolysis process: (1) catalytically decreasing theoxygen content of the biomass volatiles during the early stage ofbiomass pyrolysis; and (2) capturing oxygen to form the correspondingmetal oxide. (As described below, the metal oxide can then beregenerated to metal form).

FIG. 1 is a process block flow diagram (BFD) of the basic steps in amicrowave-based pyrolysis process for preparing fuels, using thefeedstock described previously. (Some of the steps are optional, asexplained below). The pyrolysis system is generally shown as element 10in the figure. The feedstock 12 can be contained in a feed hopper (notshown). The material can then be introduced into a conversion reactor(pyrolysis reactor) 14, by known techniques, e.g., pumps, conveyors,screw feeders, or various combinations thereof. In some embodiments, thefeedstock material can be ground to smaller particles before being sentto the reactor. Suitable grinders or shredders are commerciallyavailable. Moreover, in some embodiments, the feedstock can be directedthrough a pre-heater (not shown), prior to entering reactor 14.

As alluded to previously, the particular type of conversion reactor canvary, depending on many of the factors noted above. Non-limitingexamples of such reactors include tubular reactors, cyclone reactors,rotating cone reactors, ablative reactors, or fluidized bed reactors.Fluidized bed reactors are preferred in some embodiments. Some of thesereactors are known in the art, and described in various references,e.g., “Fast Pyrolysis of Biomass in a Fluidized Bed Reactor: In SituFiltering of the Vapors”, E. Hoekstra et al, Ind. Eng. Chem. Res., 2009,48 (10), pp. 4744-4756, American Chemical Society, 2009; and U.S. Pat.No. 5,961,786 (Freel et al), mentioned previously.

As mentioned above, the feedstock material 12 is heated in the reactor14 with microwave energy from a microwave source 16. Microwave systemsare known in the art, and described in many references. Non-limitingexamples include U.S. Pat. No. 7,705,058 (Coutinho et al) and U.S. Pat.No. 7,666,235 (Learey et al), which are incorporated herein byreference. Typically, the microwave energy is generated in at least onemagnetron, through a wave guide (not shown). However, many variations ofmicrowave systems are possible.

The microwave power required for pyrolysis will depend on variousfactors, such as the type of feedstock being treated; and the volume ofthe feedstock. As a very general illustration, the overall energyrequirement for a process producing about 30,000 bpd of liquid fuel(i.e., after upgrading) is in the range of about 15 MW to about 30 MW.In order to satisfy this energy requirement, the microwave energy isusually generated at a power level in the range of about 150 kilowattsper pound (kW/lb) to about 1,00 kilowatts per pound of solid feedstockmaterial. In some instances, the microwave energy is generated at apower level in the range of about 30 kilowatts per pound (kW/lb) toabout 500 kilowatts per pound. The frequency of the microwave energygenerated will depend in large part on other equipment parameters, andon composition of the feedstock. Usually, the frequency is 800 MHz or2.45 GHz.

The electricity needed to produce the energy for the microwave systemcan be supplied by any energy source 18, or by combinations of energysources. Examples include conventional electrical generators. In someembodiments, the electricity can be provided by a renewable energysource, such as wind, solar, thermal, hydro, or other sources ofrenewable energy. In this manner, the overall energy system 10 can beself-contained, without requiring energy from outside sources (i.e.without being connected to the “grid”).

With continued reference to FIG. 1, a transition metal source, such as ametal regeneration reactor 20, can supply the transition metal toreactor 14, e.g., via conduit/route 22. As mentioned above, thetransition metal can be obtained from a number of sources, in a numberof different forms. During the pyrolysis process, the transition metalis oxidized, forming one or more corresponding oxides of the metal.

As alluded to previously, the primary products of pyrolysis arepyrolysis oil, light gases (e.g., light hydrocarbon gases), and char.(In some embodiments, the initial pyrolysis products are primarily onlychar and a product vapor. After removal of the char, the vapor can becondensed to the liquid product, i.e., the bio-oil). The proportions ofeach of these constituents can vary considerably. In some embodiments,the amount of oil produced, based on total product yield, is about 60%to about 80% by weight. The amount of char produced is about 10% toabout 15% by weight; while the amount of gas produced is about 10% toabout 25%, by weight. The content of the gaseous component will dependin part on the initial composition of the feedstock. Frequently, thegaseous component comprises hydrogen, carbon monoxide, and lighthydrocarbons, e.g., linear, branched, or cyclic hydrocarbons containingless than about 6 carbon atoms in the longest continuous chain. Thesolid components exiting the pyrolysis reactor usually comprise char,ash, and the transition metal oxide(s), e.g., iron oxide (FeO).

In some preferred embodiments, the transition metal can be regeneratedfrom the oxide, after pyrolysis. The transition metal oxide can first beseparated from the other pyrolysis products of reactor 14 byconventional techniques. For example, a cyclone or similar device can beused, since the transition metal is typically heavier than the char orash products. Alternatively, a magnetic separator may be useful, sincethe iron oxide is ferromagnetic, while the char component and most ofthe ash components are not magnetic. Separation of the metal oxide isdesirable, since alkali metals in the ash can sinter in there-generation reactor 20, forming a deactivating coating on the surfaceof the transition metal particles.

In preferred methods, the transition metal is regenerated by chemicalreduction of the metal oxide. Regeneration can take place withinregeneration reactor 20. This reactor can be a separate vessel from thatused to store and deliver the transition metal to conversion reactor 14from other sources.

Chemical reduction of the transition metal oxide is an endothermicprocess. For example, in the case of an iron-based material, thereduction from iron oxide (FeO) to metallic iron may require about 1.2kJ per gram of the oxide. This energy an be supplied from a number ofsources, e.g., any combustion-based source. However, in some preferredembodiments, the energy is supplied by the combustion of some of thehydrocarbon fuel produced in the pyrolysis reaction. Pathway 24 is meantto illustrate, in simple form, the diversion of some of the pyrolysisproduct to regeneration reactor 20. Moreover, in some embodiments, thecombustion of the portion of the pyrolysis products is carried out in avessel separate from reactor 20, though in communication therewith. Thishelps to ensure that a low partial pressure of oxygen can be maintainedin the regeneration reactor.

FIG. 2 is provided to illustrate a general mechanism for the oxidationand regeneration of the transition metal, during the pyrolysis process.The mechanism can be thought of as a “chemical looping” process. It issomewhat analogous to the unmixed combustion processes for oxidizingunoxidized fuels in combustion systems, taught, for example, in U.S.Pat. No. 5,339,754 (R. Lyon), which is incorporated herein by reference.

FIG. 2 plots the fraction of the transition metal (in this case, iron)as a function of temperature, under equilibrium conditions, for atypical biomass pyrolysis reaction. (As described previously, thetransition metal reacts with oxygen contained in the feedstock, and thetransition metal oxide is formed. This oxide is then reduced back to themetal, in the regeneration reactor). As shown in the figure, theoxidation and reduction of iron take place at different temperatures,which is the key parameter. Moreover, the reactions occur atsub-stoichiometric conditions, i.e., with the amount of oxygen beingless-than-stoichiometric. FIG. 2 shows that, under reducing conditionsat about 700-800° K., equilibrium conditions favor oxygen transfer toiron. At higher temperatures, the same equilibrium conditions favoroxygen removal from iron, thereby providing a mechanism for ironregeneration.

As also shown in FIG. 1, other byproducts of pyrolysis, such as the ashproducts and char products, can be removed from the conversion reactor14, via pathway 26, in a number of ways. As an example, these byproductscan be vitrified by conventional techniques, to form an inert material.Frequently, vitrification is carried out in a furnace of some type(e.g., vitrification reactor 28), followed by rapid cooling in a fluidlike water. As described in U.S. patent application Ser. No. 12/478852(Lissianski et al, filed on Jun. 5, 2009, and incorporated herein byreference), the char can be used in other combustion or gasificationsystems. It can also be used as fertiliser—especially when the feedstockis made up of significant amounts of biomass.

In some specific embodiments, at least a portion of the pyrolysisproducts (e.g., the pyrolysis oil and light gases) is subjected to atleast one upgrading step 30 (FIG. 1). A typical upgrading procedure isdescribed in detail in U.S. Patent Application Publication 2009/0259082,and involves a hydro-treating step. Hydro-treating can be followed by ahydro-isomerization step, and then a separation step, which separatesvarious components of the isomerization products. The upgrading stepsare designed to produce one or more deliverable fuel products 32.

The hydro-treating step differs significantly from the hydro-treatingoperations which are common in the petroleum industry, i.e., in therefining of crude oil. Petroleum-based feedstock includes asphalt,aromatics, or ring compounds, with carbon chain lengths of about C₃₀. Incontrast, bio-oils typically include relatively high levels of compoundssuch as triglycerides, fatty acids and other esters of fatty acids. Inthe case of bio-oil processing, hydro-treating is primarily employed toeffect hydro-deoxygenation. Oxygen does not add to the heating value ofthe fuel product and hence, it is desirable to keep the concentration ofoxygen at relatively low levels, as described previously. In someembodiments, the oxygen concentration is reduced to levels which areless than about 0.01% by weight, after the pyrolysis and hydro-treatingsteps are carried out.

The hydro-treating reaction also involves the saturation of the doublebonds. It removes the double bonds from the components of bio-oil, andthis reduces the problems associated with unsaturated compounds thatwould readily polymerize and cause fuel instability and problems incombustion. The hydrogen reacts with the triglycerides to formhydrogenated triglycerides. The hydrogenated triglycerides further reactwith hydrogen to form diglycerides, monoglycerides, acids, and waxes.These materials further react with hydrogen, to undergohydro-deoxygenation to form linear alkanes. As described herein, some ofthe products include propane, as well as linear C₁₆ and C₁₈ alkanes.

Other details regarding exemplary hydro-treating operations are providedin U.S. Patent Application Publication 2009/0259082. Transition metalsulfides are generally used as catalysts for hydro-treating, e.g.,sulfides of NiMo or CoMo. Typical temperatures maintained duringhydro-treating are between about 200° C. and about 450° C. A typicalpressure range for the hydro-treating operation is between about 10 barand about 80 bar. In some embodiments, the pressures of about 40 toabout 60 bar, and temperatures of about 280° C. to about 350° C., may bemore preferred. Moreover, an illustrative reaction scheme for thehydrogenation of a triglyceride-based vegetable oil, such as soybeanoil, is provided in the '082 publication.

The hydro-treating reaction produces water molecules, CO₂, and somelight hydrocarbons such as propane, in addition to (long chain) linearalkanes, which are the desired products. These additional products canbe separated from the linear alkanes, before the step ofhydro-isomerization. The water may be used for various purposes, e.g.,to form steam, which can be used in a gasification reaction, forexample. The light hydrocarbons like propane can be used as a fuel togenerate heat energy, e.g., in a steam generating system like a boiler.

As described in U.S. Patent Application Publication 2009/0259082, thehydro-treating reaction is usually followed by a hydro-isomerizationreaction (sometimes referred to herein as simply an “isomerizationreaction” or “isomerization”). In this step, the linear alkanes presentin the mixture are reacted with hydrogen, in the presence of specifiedcatalysts, to produce branched compounds, i.e., branched isomers. Thebranched isomers of light paraffins have higher octane numbers than thecorresponding normal straight alkanes and hence, are often a desirablecomponent of the fuel. For products such as jet fuel, the specificationsrequire that the octane number for a lean mixture of the grade 80 fuelshould be about 80 at minimum. (The contents of ASTM Standard D 7566-09(“Standard Specification for Aviation Turbine Fuel ContainingSynthesized Hydrocarbons”, © ASTM International, 2009, are incorporatedherein by reference). In some embodiments, the fuel composition containsa specified proportion of iso-saturated alkanes and cyclo-saturatedalkanes (the total) to normal-saturated alkanes. In this regard, theteachings of U.S. patent application No. 12/710955 (Daniel Derr et al,filed on Feb. 23, 2010) is incorporated herein by reference.

A number of different types of catalysts can be used in thehydro-isomerization step. Examples are provided in U.S. patentapplication Publication 2009/0259082, and include noble metal catalystssuch as platinum. Other examples are zeolite materials, or solid acidcatalysts. In some embodiments, the catalyst system comprises acombination of silica-alumina, alumina, and at least one group VIIImetal, i.e., iron, cobalt, nickel, ruthenium, rhodium, palladium,osmium, iridium, or platinum. Such a catalyst system is described inpatent application 12/344,291 (Deluga et al), filed on Dec. 26, 2008,and incorporated herein by reference. In one more specific example, thecatalyst composition comprises:

about 5 weight percent to about 70 weight percent of silica-alumina;

about 30 weight percent to about 90 weight percent alumina; and

about 0.01 weight percent to about 2.0 weight percent of a group VIIImetal.

Such a catalyst composition can further comprise about 5 weight percentto about 70 weight percent of a zeolite. In some embodiments, thezeolite comprises silicon and aluminum; at a ratio (weight) in the rangeof about 1.0 to about 300. Non-limiting examples of the zeolites are asfollows: zeolite Y, zeolite beta, ferrierite, mordenite, zeoliteZSM-22/23, and zeolite ZSM-5.

In terms of other operating parameters for the hydro-isomerization step,typical temperatures are maintained in the range of about 200° C. andabout 450° C. A typical pressure range for the operation is betweenabout 10 bar and about 80 bar. In some embodiments, a pressure range ofabout 40 to about 60 bar, and a temperature range of about 275° C. toabout 350° C., may be more preferred. As also described in Publication2009/0259082, the isomerization reaction involves rearrangement of thealkyl groups.

As also mentioned previously, a separation step is often undertaken,after hydro-isomerization. This step is very useful in separating thevarious components which constitute the isomerization products. The stepcan comprise one or more procedures. As an example, different fractionsof the isomerization products can be separated, based on boiling pointranges. Exemplary techniques include flash distillation, fractionation,and the like.

The separation step can also involve a flash operation, wherein theproducts of the hydro-isomerization step are usually sent at highpressure to a flash vessel, and are then subjected to a low pressureenvironment. Typically, two streams are formed—the gaseous stream richin more volatile components, and the liquid stream, which contains ahigher percentage of lower volatile components. A cascade of suchseparations, or a distillation column, may be employed. The separationstep may also include a fractionation column, where multiple components(e.g., light hydrocarbons) can be separated in a single column.Moreover, in some embodiments, at least a portion of the lighthydrocarbon generated in the hydro-treating operation, or the lighthydrocarbon generated in the hydro-isomerization operation, is sent tothe separation operation. (Both light hydrocarbon streams can be sent aswell). In general, the separation step allows for greater control of thecomposition of the product fuel.

While the invention has been described with reference to an exemplaryembodiment, it will be understood by those skilled in the art thatvarious changes may be made, and equivalents may be substituted forelements thereof, without departing from the scope of the invention. Inaddition, many modifications may be made to adapt a particular situationor material to the teachings of the invention, without departing fromthe essential scope thereof. Therefore, it is intended that theinvention not be limited to the particular embodiment disclosed as thebest mode contemplated for carrying out this invention, but that theinvention will include all embodiments falling within the scope of theappended claims.

What is claimed:
 1. A method for producing a fuel composition from afeedstock that includes biomass, municipal solid waste (MSW), or acombination thereof, said method comprising the steps of: pyrolyzing thefeedstock in the presence of a transition metal using microwave energy,wherein a level of oxygen in at least one pyrolysis product is reduced,and wherein the transition metal is oxidized to form a transition metaloxide; and regenerating the transition metal by subjecting thetransition metal oxide to a reduction reaction in a regenerationreactor, wherein regeneration of the transition metal is carried out bya reduction reaction which reduces the transition metal oxide, andwherein at least a portion of the energy required for the reductionreaction is supplied by combustion of at least one pyrolysis product. 2.The method of claim 1, wherein the pyrolysis is carried out under plasmaconditions, using the microwave energy.
 3. The method of claim 1,wherein the transition metal is selected from the group consisting ofcopper, nickel, cobalt, manganese, iron, and zinc.
 4. The method ofclaim 1, wherein the transition metal is iron.
 5. The method of claim 1,wherein the feedstock, prior to pyrolysis, contains oxygen at a level of10% to about 50%, based on the total solids weight of the feedstock. 6.The method of claim 1, wherein the feedstock contains a pre-determinedamount of oxygen before pyrolysis; and after pyrolysis, the amount ofoxygen has been reduced by at least about 50% of the amount beforepyrolysis.
 7. The method of claim 1, wherein pyrolysis of the feedstockproduces a composition comprising bio-oils, light hydrocarbons, andchar.
 8. The method of claim 1, wherein the at least one pyrolysisproduct which is combusted for the reduction reaction comprises lighthydrocarbons.
 9. The method of claim 1, wherein at least a portion ofthe pyrolysis product is subjected to at least one upgrading step. 10.The method of claim 9, wherein the upgrading step compriseshydro-treating.
 11. The method of claim 10, wherein the hydro-treatingstep is followed by a hydro-isomerization step.
 12. The method of claim11, wherein the hydro-isomerization step is followed by at least oneseparation step, to separate at least some of the isomerizationproducts.
 13. An integrated process for producing a fuel compositionfrom a feedstock material that includes at least one of biomass andmunicipal solid waste, the process comprising the steps of: a)pyrolyzing the feedstock in the presence of a transition metal usingmicrowave energy, wherein a level of oxygen in at least one pyrolysisproduct is reduced, and wherein the transition metal is oxidized to forma transition metal oxide; wherein the at least one pyrolysis productcomprises bio-oils, light hydrocarbons, and char; b) regenerating thetransition metal by subjecting the transition metal oxide to a reductionreaction in a regeneration reactor, wherein regeneration of thetransition metal is carried out by a reduction reaction which reducesthe transition metal oxide, and wherein at least a portion of the energyrequired for the reduction reaction is supplied by combustion of atleast one pyrolysis product; and c) upgrading the bio-oil product to aliquid fuel, by subjecting the bio-oil to an upgrading processcomprising hydro-treating, following by hydro-isomerization andseparation of isomerization products.
 14. A system for producing a fuelcomposition from a feedstock material that includes at least one ofbiomass and municipal solid waste (MSW), the system comprising: (i) apyrolysis reactor, adapted to accept a feedstock of biomass or municipalsolid waste (MSW), or combinations thereof; and to convert the feedstockto pyrolysis products in the presence of a transition metal; (ii) amicrowave source adapted to supply microwave energy to the pyrolysisreactor; (iii) a regeneration reactor in communication with thepyrolysis reactor, to supply a selected amount of the transition metalduring pyrolysis by regenerating the transition metal in a reductionreaction, wherein at least a portion of the energy required for thereduction reaction is supplied by combustion of at least one pyrolysisproduct; and (iv) at least one upgrading unit in communication with thepyrolysis reactor, to convert at least one of the pyrolysis products toa liquid fuel composition.